System and method for creating customized products

ABSTRACT

The present invention relates to a system and method for creating customized products using a product identification device. In some embodiments, the process involves receiving an aggregate order for yearbooks, creating a master list associated with the aggregate order and including single orders, associating at least one number with each single order, manufacturing a first portion of a yearbook for each single order with a first identifier associated with that portion and also being associated with the at least one number, manufacturing a second portion of the yearbook for the single order with a second identifier associated with that portion and also being associated with the at least one number, and combining the first portion with the second portion.

FIELD OF THE INVENTION

This invention relates generally to a system and method for creatingcustomized products, and more specifically to a system and method forcreating customized products using a product identification device.

BACKGROUND OF THE INVENTION

Consumer products are being offered with common and customized portions.A challenge with manufacturing such products is associating the correctcustomized portions with corresponding common portions. For example, inyearbooks, a large portion of the yearbook is common to a school withstudents or parents being offered the opportunity to incorporatecustomized pages, a customized cover, and other customized elements tocreate a customized yearbook. In manufacturing such customized yearbook,the correct customized elements should be associated with the correctcommon yearbook.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a system and method for creatingcustomized products using a product identification device. In someembodiments, the process involves receiving an aggregate order foryearbooks, creating a master list associated with the aggregate orderand including single orders, associating at least one number with eachsingle order, manufacturing a first portion of a yearbook for eachsingle order with a first identifier associated with that portion andalso being associated with the at least one number, manufacturing asecond portion of the yearbook for the single order with a secondidentifier associated with that portion and also being associated withthe at least one number, and combining the first portion with the secondportion. It is to be appreciated that, in some embodiments, one or moreof these steps may not be included and/or other steps not listed may beincluded.

While multiple embodiments are disclosed, still other embodiments of thepresent teachings will become apparent to those skilled in the art fromthe following detailed description, which shows and describedillustrative embodiments. As will be realized, the teachings are capableof modifications in various obvious aspects, all without departing fromthe spirit and scope of the present teachings. Accordingly, the drawingsand detailed description are to be regarded as illustrative in natureand not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a process for creating a customized product includinga first portion and a second portion, in accordance with one embodimentof the present invention.

FIG. 2 illustrates a process for creating customized products, inaccordance with one embodiment of the present invention.

FIG. 3 illustrates numbers that may be associated with a single order,in accordance with one embodiment of the present invention.

FIG. 4 illustrates possible locations for application of the RFID chipto the book block in accordance with some embodiments of the presentinvention.

FIG. 5 illustrates possible locations for application of the RFID chipto the book block in accordance with other embodiments of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a system and method for creatingcustomized products using a product identification device. The systemand method enable tracking of the customized product such that it may beappropriately manufactured as well as to ensure integrity and quality ofthe manufacturing process. More specifically, in one embodiment, thesystem and method enable tracking of a book that is customized to aparticular individual during all processes require to make that book.

The system and method may be used for manufacturing a variety ofconsumer products including, for example, yearbooks, memory books, photobooks, commercial books, magazines, and calendars. The system and methodare generally suited for manufacture of any item comprising multipleportions that are formed separately at concurrent or separate parts ofthe method. For example, in one embodiment, the system and method may beused for manufacture of an item formed in two parts. For example, in oneembodiment, the system and method may be used for manufacture of an itemthat includes a first portion and a second portion wherein the firstportion and the second portion are coupled or adjoined. The system andmethod facilitate tracking of each portion through the manufacturingprocess and verification of the portions prior to, and after, coupling.It is to be appreciated that the system and method may be used tomanufacture an item comprising any number of portions and that twoportions are described herein only for purposes of illustration.

Accordingly, the system and method may be used for manufacturingyearbooks, memory books, or other books. Yearbooks generally are hardcover, have 50 to several hundred pages (page range may vary), includeendsheets and tip-ins, and may be produced in color or in black andwhite. Memory books generally are often soft cover, have 8-64 pages(page range may vary), and may be produced in color or in black andwhite. Further, the present invention may be applied to any customizedproduct—including books or other output. Thus, while the presentinvention is generally described in terms of yearbooks, the invention isequally suited for manufacture of other customized products. Theinvention may further be used for aggregating a plurality of products.

Yearbooks are commonly used to document a particular year at a school.Increasingly, students and parents are given the opportunity toincorporate personalized elements into a yearbook. These elements mayinclude custom pages, custom endsheets, a custom cover, or otherelements. In some schools, a DVD or other add-on may be included with ayearbook.

FIG. 1 illustrates a process 1 for creating a customized productincluding a first portion and a second portion. An order for thecustomized product is processed [block 2]. Such processing may comprisereceiving an order via computer, receiving a paper order, crafting anorder, or otherwise developing information regarding specifics for theproduct. An order number (also referred to herein generically as anumber) is associated with the order [block 3]. One or more trackingnumbers (also referred to herein as identifiers) are associated with theorder number [block 4]. A first portion of the product is manufacturedwith the tracking number associated therewith [block 5]. A secondportion of the product is also manufactured with the tracking numberassociated therewith [block 6]. It is to be appreciated that thetracking number associated with the first portion and the trackingnumber associated with the second portion may be the same trackingnumber or may be different tracking numbers so long as the trackingnumber is associated with the order number. The first portion and thesecond portion are then combined [block 7]. In some embodiments, suchcombination may result in the final product as ordered. It is to beappreciated that by using RFID, bar code, and related technology forcorrelating the tracking number(s) with the first portion and the secondportion, tracking of production of the first portion and the secondportion may be automated using machine readers such that humaninteraction is substantially eliminated.

One application for the system and method involves manufacture ofcustomized books such as yearbooks or memory books. Manufacture of ayearbook includes manufacture of a common portion of the yearbook,manufacture and incorporation of a customized portion of the yearbook,and manufacture and attachment of a cover (customized or common). Usingthe system and method, each of the common portion, the customizedportion, and the cover may be tracked and coordinated. Further, the timeeach portion entered and exited a particular machine in themanufacturing process may be tracked such that any failure of machinerycan be determined.

FIG. 2 illustrates a process 10 for creating customized products inaccordance with one embodiment. As shown, the process involves receivingan aggregate order for yearbooks [block 12], creating a master listassociated with the aggregate order and including single orders [block14], associating at least one number with each single order [block 16],associating a first identifier with the at least one number [block 18],manufacturing a first portion of a yearbook for each single order andcorrelating the first identifier with the first portion of the yearbook[block 20], associating a second identifier with the at least one number[block 22], manufacturing a second portion of the yearbook for thesingle order and correlating the second identifier with the secondportion of the yearbook [block 24], and combining the first portion withthe second portion [block 26]. In various embodiments, one or more ofthe listed steps of FIG. 1 may not be performed. Further, in someembodiments one or more steps not listed in FIG. 1 may be performed.Again, while manufacture of a yearbook is described, the process mayalternatively be applied to any product having a first portion and asecond portion wherein the first portion and the second portion arecombined to form the final product.

As used herein, an order may refer to a single order (for example for asingle student) or an aggregate order (for example for an entireschool). For the purposes of illustration, a single student order willbe referred to as a single order and a school order will be referred toas an aggregate order. Generally, an aggregate order may comprise aplurality of single orders. The plurality of single orders may be placedon a master list such that the orders may be more easily tracked. Insome cases, a student may order only a yearbook (customized or common tothe school). In other cases, the student may order a plurality of itemssuch as a yearbook, graduation announcements, cap and gown, etc. WhileFIG. 2 specifically illustrates receiving an aggregate order foryearbooks [block 12], creating a master list associated with theaggregate order and including single orders [block 14], and associatingat least one number with each single order [block 16], in someembodiments other means for assimilating and tracking orders may beused.

When an order (single or aggregate) is received, one or more numbers maybe assigned to each single order. FIG. 3 illustrates numbers that may beassociated with a single order in accordance with one embodiment. Asshown, one or more of a sequence number 30, a bar code tracking number32, and an RFID tracking number 34 may be associated with each singleorder. In some embodiments, the sequence number may be referred to as anorder number. In embodiments using an RFID tracking number, more thanone RFID tracking number may be associated with each single order.Generally, each of the sequence number, bar code tracking number, andRFID tracking number is unique during the manufacturing process and isassociated with each of the other numbers for the single order.

Referring back to FIG. 2, associating at least one number with eachsingle order [block 16] may comprise associating a sequence number withthe order. Generally, a sequence number may associated with every itemin that order. For example, the sequence number may be associated with acustomized yearbook, customized graduation announcements, and a commoncap and gown. Thus, all items included in that order may be aggregatedfor a single shipment, for example. In some embodiments, the sequencenumber may be a hexidecimal (26 digit) random number. The sequencenumber is associated with the single order and entered on the masterlist.

As shown in FIG. 2, a first portion is manufactured and a second portionis manufactured [blocks 20 and 24]. Generally as described herein thefirst portion may be a book block and the second portion may be a cover.The system and method is particularly suited for products such asyearbooks having common portions and customized portions. Such commonportions and customized portions may be within the book block or thecover. For example, a book block may include a plurality of pages commonto every yearbook as well as one or more pages customized to a specificstudent. It is to be appreciated that this description may alternativelybe applied to other items.

As is described more fully below, first and second identifiers areassociated with a number, the first identifier being associated with thefirst portion and the second identifier being associated with the secondportion. The identifiers are associated with one of the numbers assignedto the single order. At some points in the manufacturing process, theidentifier may be a bar code. At other points in the process, theidentifier may be an RFID chip. It is to be appreciated that otheridentifiers may alternatively be used as would be known to one skilledin the art.

Production of the Book Block

As previously discussed, at least one number is associated with eachsingle order (block 16 of FIG. 2). In some embodiments, the at least onenumber may be a sequence number. Thus, the sequence number may beassociated with each single order and further numbers correlated to thesequence number. For example, a tracking number may be correlated to thesequence number.

The tracking number is a number that is physically placed on the bookblock, for example via a bar code or RFID chip. A tracking number mayassociated with each book block, including book block for books thatwill not have a customized portion. The tracking number may be the samenumber as the sequence number or may be a different number. In someembodiments, a first tracking number associated with the book block maybe a bar code tracking number. In a specific embodiment, the bar codetracking number comprises the year, customer/job number, signaturenumber, a 4 digit sequential number for a student, and a rev level ofthe signature (indicating the revision number).

In some embodiments, manufacturing a first portion of a yearbook foreach single order [block 20] may comprise manufacturing a book block.Production of the book block may begin with printing of a signature at adigital press. Correlating the first identifier with the first portionof the yearbook [block 20] may thus comprise correlating a firstidentifier with the book block. In a specific embodiment, a bar code(comprising the bar code tracking number) may be printed on thesignature. In alternative embodiments, other tracking mechanisms, suchas an RFID chip, may be used and a bar code may not be printed on thesignature. In some embodiments, the bar code is printed on a page of thebook block. In alternative embodiments, the bar code may be printed onany portion of the book block including portions where the bar code maybe removed and/or portions where the bar code may be permanentlyincorporated in the book. Similarly, an RFID chip may be placed at anysuitable portion of the book block. For example, the RFID chip may beplaced in a gutter (or deep fold) of a signature of a book block.

Producing of a book block wherein the first identifier is a bar codewill now be described. It is to be appreciated that production maydiffer in ways appreciated by one skilled in the art when the firstidentifier is a tracking mechanism other than a bar code. The bar codeis scanned and the associated book portion tracked through folding,gathering, sewing, and tipping. More specifically, the bar code is usedfor tracking the book through collation of pages into a book block. Insome embodiments, the bar code (or other tracking mechanism) may be readat each production step of the book block to record the time the booktravels through a machine at that step and to gather specificinstructions for the book at each step where appropriate. Accordingly,if it is determined that the there is a quality issue with the bookmanufacturing process—for example an issue with sewing of the bookblock—the exact time of the issue can be determined and all book blocks(or book elements) that were processed through that machine after it isdetermined that the quality issue arose.

In a specific embodiment, near the final stages of production of a bookblock using a bar code tracking number, the system transitions from barcode tracking to RFID tracking. Generally, an RFID chip is then appliedto the book block and the bar code is removed or obscured.

In one embodiment of transition from bar code tracking to RFID tracking,application and removal is done after a final machine in the book blockprocessing. For example, as the book block comes off of the gluingmachine, a device may be provided for opening the book to the pagehaving the bar code and reading the bar code (or simply reading the barcode on an outer portion of the book block if the bar code is appliedthereon). Reading of the bar code causes a signal to be generated andsent to an RFID printer. The RFID printer then prints and applies anRFID tag to the book block. In some embodiments, the RFID chip isapplied to the spine of the book block such that the chip is covered andcannot be seen when the cover is applied to the book. In otherembodiments, the RFID chip is applied to the front of the book block orto the back of the book block. FIGS. 4 and 5 illustrate possiblealternative locations for application of the RFID chip 40 to the bookblock 42. FIG. 4 illustrates locations on the front 44 and spine 46 ofthe book block 42. FIG. 5 illustrates locations on the back 48 and thegutter 50 of the book block 42. It is to be appreciated that inembodiments wherein only one RFID chip is applied to the book block,only one of these locations will be used. In other embodiments, no RFIDchip may be applied directly to the book block and an RFID chip may beassociated with the book block when the cover may be applied to the bookblock. In some embodiments, a first RFID chip is applied to the bookblock and a second RFID chip is applied to the cover, described morefully below.

The RFID chip has an associated tracking number. The RFID trackingnumber may be the same as the bar code tracking number, may be thesequence number, or may be a different number that is associated withthe sequence number. In one embodiment, the RFID printer applies theRFID tag to the front of the book. After application of the RFID chip,the bar code may be removed from the book. This may be done by trimmingthe portion of the page including the bar code. Alternatively, the barcode may be otherwise obscured.

In some embodiments, a label may be provided on one side of the RFIDchip. The label may include information associated with the single orderfor the book including, for example, the ordering student's name, thebar code, the sequential number associated with the student, and schoolinformation. In some embodiments, some of the information on the labelmay be printed sufficiently darkly that that information may be seenthrough covering of the RFID chip. For example, where an endsheetcouples the book block to the cover and the endsheet covers the RFIDchip, the student's name may be printed sufficiently darkly that thestudent's name is visible through the endsheet.

At various points during the manufacturing process, the identifier (barcode, RFID chip, or other tracking mechanism) may be used to conduct aspart of a pass/fail test. For the test, a reader reads the identifier todetermine the tracking number associated with the identifier. Inembodiments using an RFID chip, the RFID chip is activated such that itmay be read to determine the RFID tracking number. The determinedtracking number is then compared to the master list to ensure that thebook component (pages, book block, cover, etc.) is the correct bookcomponent. If the book element does not pass the pass/fail test,processing of that book is halted. Thus, for example, the RFID chipand/or the bar code may be read before the bar code is removed from thebook block to ensure that the correct RFID chip was associated with thebook block.

Production of the Cover

In some embodiments, manufacturing a second portion of the yearbook forthe single order [block 24] may comprise manufacturing a cover for ayearbook and correlating the second identifier with the second portionof the yearbook [block 24] may comprise printing a bar code identifierand/or placing an RFID chip identifier on the cover. Covers may becustomized, thus specific to one student, or may be common. Generally,covers comprise a printed portion that is wrapped around a facing board.When the printed portion is printed, a bar code identifier may beprinted on a side that is facing the board as assembled. For example,the bar code identifier may be printed on the printed portion such thatthe bar code is on the lip that is folded in on the facing board asassembled. The bar code number on the bar code printed on the cover maybe the same as the bar code number on the bar code printed on the bookblock, if used. Alternatively, a different bar code number associatedwith the sequence number may be used. In some embodiments, an RFID chipidentifier may additionally or alternatively be applied to the cover,such as to the inside spine of the cover, to the inside front of thecover, to the inside back of the cover, or to other suitable location onthe cover. The RFID chip may be embedded between the cover board and theprinted cover material or between the cover board and the endsheet. SuchRFID chip has an associated RFID tracking number. The associated RFIDtracking number may be the same as the tracking number for the RFID chipof the book block or may be different. Each of the bar code trackingnumber and RFID tracking number of the cover is associated with thesequence number or otherwise associated with the single order.

The cover may undergo further operations such as embossing, graining,etc. As the cover proceeds through different stations, the identifier(bar code or RFID chip) is read and matched to the sequence number todetermine the appropriate operation based on the master list. Theequipment for each process thus receives instructions based on themaster list.

Association of the Cover with the Book Block

Referring back to FIG. 2, the first portion and the second portion arecombined [block 26]. Thus, in one embodiment, after the cover has beenproduced, the cover is applied to the finished book block. Applicationof the cover to the book block may be referred to as casing. At casing,a pass/fail test is conducted. A reader verifies that the book blocksare in sequence. In some embodiments, the sequence may reflect thesequence of the master list. If a book block is out of order, the bookblock feeder to the casing system is shut down but the remainder of thesystem may continue. Thus, book blocks and covers already fed to thecasing system may be processed. Likewise, a reader verifies that thecovers are in sequence. If a cover is out of sequence, the hopper to thecasing system is shut down but the remainder of the system may continue.Thus, book blocks and covers already fed to the casing system may beprocessed. If the book block feeder is shut off, the hopper is likewiseshut off. If the hopper is shut off, the book block feeder is likewiseshut off

After sequence has been verified, the book block feeder feeds bookblocks to the casing system and the hopper feeds covers to the casingsystem. Shortly before the cover is glued to the book block, a furtherset of readers reads the identifiers of the book block and the cover.These readers again verify sequence based on comparison to the masterlist. If the sequence read by each reader does not match, the casingoperation is shut off. If the sequence read by each of the readers doesmatch, the casing operation proceeds.

When the book block is fixed to the cover, the identifying mechanism onthe book block is automatically associated with the cover. For example,if an RFID chip has been applied to the front of the book block, theRFID chip is automatically associated with the book block when the bookblock is fixed to the cover. In some embodiments wherein an RFID chip isapplied to the book block and an RFID chip is applied to the cover, theRFID chips may be applied such that they substantially align and stackwhen the book block is placed in the cover, thereby accentuating theplacement of the RFID chips.

Post Processing

After casing, the book proceeds to activation station where the RFIDchips (if RFID chip identifiers were used, alternatively each of theother tracking mechanisms are read) for both the book block and thecover are activated. A reader then verifies that both chips match andthat the chips match the book. If matching is confirmed, a label isprinted and applied to the book. The label may be printed withidentifying information such as the name of the student, the sequencenumber, etc. In some embodiments, after casing operations may beperformed and these may be indicated on the label.

If further post processing, such as laser die cuts, tip ins, embossing,extra content, etc., the book may be directed to the appropriate machinefor such processing. That machine reads the RFID chips associated withthe book to compare with the master list and determine instructions.

In some embodiments, a single order may include further components to beadded to the book. For example, a student may order the book, graduationannouncements, CDs, DVDs, or other. These components may similarly havetracking devices correlated to them where the components are customized.Alternatively, if the component is a common component, such as agraduation cap, no tracking device may be associated with it. Eachcomponent may be identified with a sequence number and all componentshaving that sequence number aggregated. In some embodiments, a pick packstation may be implemented such that a reader scans the chip and outputswhat items should be added to the book.

Storage and Shipping

For shipping, books are packaged in a box. The books may be packaged insequence or other. The entire box can be scanned to read the RFID chipsof the books in the box. These books may then be checked against themaster list for an aggregate order. The chips are thus used to verifycompletion of an order. For at least this reason, it is useful toassociate an RFID chip with common books as well as customized books.

If the books are not shipped immediately, they may be warehoused. Suchwarehousing may be individually or in boxes. The RFID chip of each bookmay be used to catalogue placement of the book in a warehouse. Thus,when it is time to ship the book, the chip may be read or entered tolocate the book or box and process to shipping.

A reader may be provided at the truck for receiving skids of books withthe boxes scanned and a bill of laden and/or other shipping documentsprinted inventorying regarding what is shipped from the warehouse. Anadvance shipping notice may be sent to the school based on the readingof the truck to provide advance notice of the likely delivery date. Inthis way, schools may be notified of exact time and place of shipment ofbooks.

Although the present invention has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

What is claimed is:
 1. A method for creating a customized productcomprising: receiving an aggregate order for yearbooks; creating amaster list associated with the aggregate order and including singleorders, associating at least one, number with each single order;manufacturing a first portion of a yearbook for each single order with afirst identifier associated with that portion and also being associatedwith the at least one number; manufacturing a second portion of theyearbook for the single order with a second identifier associated withthat portion and also being associated with the at least one number; andcombining the first portion with the second portion.
 2. The method ofclaim 1, wherein the at least one number comprises a sequence number andmay be used to ensure the first portion and/or the second portion are inorder in the manufacturing process.
 3. The method of claim 1, whereinthe first portion is a book block.
 4. The method of claim 3, wherein thefirst identifier is a bar code and wherein the bar code is associatedwith the at least one number.
 5. The method of claim 4, furthercomprising removing the bar code and applying an RFID chip to the bookblock.
 6. The method of claim 5, wherein the RFID chip includes an RFIDtracking number associated with the at least one number.
 7. The methodof claim 1, wherein the second portion is a cover.
 8. The method ofclaim 7, wherein the second identifier is a bar code and wherein the barcode is associated with the at least one number.
 9. The method of claim8, further comprising applying an RFID chip to the cover.
 10. The methodof claim 9, wherein the RFID chip includes an RFID tracking numberassociated with the at least one number.
 11. A method of creating acustomized product including a first portion and a second portion, themethod comprising: processing an order for the customized product;associating an order number with the order; associating a trackingnumber with the order number; manufacturing a first portion of theproduct, wherein the first portion is associated with the trackingnumber; manufacturing a second portion of the product, wherein thesecond portion is associated with the tracking number; and combining thefirst portion and the second portion.
 12. The method of claim 11,wherein associating a tracking number with the order number comprisesassociating a first tracking number and a second tracking number withthe order and wherein the first portion is associated with the firsttracking number and the second portion is associated with the secondtracking number.
 13. The method of claim 12, wherein the first portionis a book block and the second portion is a cover.
 14. The method ofclaim 12, wherein the first tracking number is associated with the firstportion using a bar code for a first portion of the manufacturingprocess and then is associated with the first portion using an RFID chipfor a second portion of the manufacturing process.
 15. The method ofclaim 14, wherein the second portion of the manufacturing processincludes combining the first portion and the second portion.
 16. Themethod of claim 14, wherein the second tracking number is associatedwith the second portion using a bar code for a first portion of themanufacturing process and then is associated with the second portionusing an RFID chip for a second portion of the manufacturing process.17. The method of claim 16, wherein the second portion of themanufacturing process includes combining the first portion and thesecond portion.
 18. The method of claim 11, wherein manufacturing thefirst portion and manufacturing the second portion includes trackingprogress of the first portion and the second portion by reading thetracking numbers using machine readers.
 19. The method of claim 18,wherein manufacturing may be halted when reading by the machine readersestablishes an error.
 20. The method of claim 19, wherein the error is asequence error.